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Parts required from donor
vehicle Ford Sierra or Granada 86-92 (not 4x4):
Rear sub-frame complete
Hand brake lever,
Steering column,
Rack & link shaft.
Brake & throttle pedal assembly & servo.
Front hubs complete.
Engine & gearbox (save mounting rubbers)
Front door handles & catches
Wiring loom
Radiator
Battery (save the long bolt from your diff),
Brake T piece
Heater complete.
If your car has an in-tank fuel pump, we will need it for the top ring
& swirl pot to make your new fibreglass tank.
Rear Suspension:
Only disc brake type can be used.
Remove drive shafts from hubs. Undo large nuts on
hubs and separate hub from spline. Bolt hub to hub carrier and re-assemble
hub. Bolt the differential into the 3 locating lugs in the centre of the
chassis and re-fit drive shafts. The handbrake lever bolts onto the 2
metal bars on top of the centre tunnel. Connect the handbrake cables,
passing them through the 2 square tubes behind handbrake lever. Fit the
brake hoses through the 2 brackets on chassis, forward of the hubs on
the top rails.
Front Suspension:
You will need
to drill 15mm down, through the bottom ball joint hole, on the hubs to
make it fit the new ball joints. To alter the camber, screw the top ball
joint in or out. There are 2 more brackets on the top rails to hold the
brake hoses.
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| Steering
Rack: |
This is bolted to
the 2 forward plates in the centre of the chassis. |
| Steering
Column: |
Fit the lower column
bush. The column needs extending. This is done by forcing the inner triangle
shaft from the outer casing. Put the end of the shaft into a vice and tap
outer casing off by 70mm. Fit the column through the lower bush onto the
shaped plate at the top end. You will need to cut and extend the lower column
link to make it fit. |
| Brake Pedal
& Servo: |
As removed from the
car, the servo is held to the outside of the laser cut plate on the bulkhead
and bolt the pedals to the inside. All throttle pedal holes are also drilled
as Ford. |
| Brake &
Fuel Lines: |
Route the brake &
fuel lines down the inside of the centre tunnel top rails. The front brake
lines are fitted on top of the front chassis rails. The same for the wiring
loom - start with the fuse box inside the chassis frame, above and halfway
back on the driver's side from the front bulkhead. |
| Rover Engine
& Gearbox: |
Leave the front engine
mounts on. You will need Ford the gearbox mount to fit to the plate supplied
in the kit. Remove rear engine lifting eye to enable you to fit the engine
as far back as possible. Lower the front of the engine until the mounts
are about 25mm above the chassis plates. Check pulley clearance as some
Rovers have different length pulleys. You will need to remove the fan and
fit the electric type. |
| Radiator: |
Fit this as far forward
as possible to rest on the bottom chassis rails. |
| Petrol Tank: |
Petrol tank fits to
rear deck overhanging the rear by 1/2". |
Body Fitting:
Cover bulk-head with black fibre glass sheets and rivet
down. Drop the body over the chassis, pulling the side sills out until they
go under the chassis. Screw down the boot area with the body pushed forward.
Go to the front of the body, this rests on top of an angle iron. Bolt down
centrally. Next fit down inside the bonnet around the bulkhead. |
| Doors: |
Slide the door hinges
along inside the wings from the front arches and bolt to door pillars, centrally
in the slotted holes. Next push the body onto the touch hinges. Fix sill
to chassis directly underneath the hinge position, repeat the same on the
other side. Hold the doors to the hinges bolt hole marks (M8). Drill doors
and bolts to hinges. Adjust by using slot adjustment. |
| Boot: |
The boot is fitted
by using imp hinges. Holes are in the body. |
| Bonnet: |
Fit the bonnet hinges
to the body plate. Adjust using slot holes. |
| You will
need Cobra boot hinges, boot handles; BLMC Mini boot catch; Cobra bonnet
handles and cams; The front cable type door catches from a late Ford Sierra,
along with the front seatbelts complex and a Mini wiper motor assembly. |